Compositions having phosphorus-containing compounds

Abstract

Embodiments of the present disclosure provide a composition that includes a phosphorous-containing compound, a cyanate ester, an epoxy resin, and a maleimide. For the various embodiments, a viscosity of the composition increases less than 100% as measured by Gardner Bubble Viscosity a temperature of 23° C. in at least 3 days. For the various embodiments, the composition of the present disclosure can also include an aprotic solvent, such as a ketone. Embodiments of the present disclosure further include a composition that includes the phosphorous-containing compound, the cyanate ester, and the aprotic solvent. For the various embodiments, the composition can also include the epoxy resin and the maleimide. For the various embodiments, the composition does not include an aliphatic alcohol.

We claim:  
     
       1. A method of forming a composition, comprising:
 reacting an epoxy resin and a maleimide to form a compound; 
 removing an aliphatic alcohol from a phosphorous-containing compound from a reaction of: 
 at least one organophosphorus compound having a group selected from the group of H—P═O, P—H and P—OH; and 
 at least one compound having the following Formula (I): 
 Formula I: 
 [R′(Y) m′ ] m  (X—O—R″) n  wherein R′ is an organic group; Y is a functional group selected from the group of hydroxy, carboxylic acid, carboxylate, acid anhydride, amine, —SH, —SO 3 H, —CONH 2 , —NHCOOR phosphinate, phosphate or a combination thereof; X is a hydrocarbylene group; R″ is a hydrogen or a hydrocarbyl group having from 1 to 8 carbon atoms, R is alkyl or aryl group having from 1 to 12 carbon atoms; and m′, m and n are, independently, numbers equal to or greater than 1; and 
 forming a mixture of the phosphorous-containing compound with a cyanate ester in an aprotic solvent; and
 forming the composition by combining the compound and the mixture. 
 
 
     
     
       2. The method of  claim 1 , where reacting the epoxy resin and the maleimide is done at a temperature of 130° C. for 25 to 45 minutes. 
     
     
       3. The method of  claim 1 , where the aprotic solvent is a ketone selected from the group of methyl ethyl ketone, methyl isobutyl ketone or a combination thereof. 
     
     
       4. The method of  claim 1 , wherein the maleimide is selected from the group of N-Phenyl maleimide, 4,4′-bismaleimidodiphenylmethane or a combination thereof. 
     
     
       5. The method of  claim 1 , where the maleimide is N-Phenyl maleimide. 
     
     
       6. The method of  claim 1 , where the epoxy resin and the cyanate ester have a weight ratio of from 0.8:1.0 to 1.5:1.0. 
     
     
       7. The method of  claim 1 , wherein the cyanate ester has been partially homopolymerized to form a trimer. 
     
     
       8. The method of  claim 1 , where the phosphorous-containing compound is DOP-BN formed from the reaction of 6H-Dibenz[c,e][1,2]oxaphosphorin 6-oxide and a resole.